"Clearly on course for broad industrialization"

3D printing at BMW. © BMW

How do you intend to further scale additive manufacturing in the BMW Group and what are you doing specifically?
The major pre-development projects IDAM and Polyline were an important precursor to the scaling of AM applications. In these projects, the BMW Group actively helped shape the basis for scaling in the automotive sector by defining requirements, developing solutions and piloting system-integrated structures.

Automated, digitally networked process chains, open material systems and open interfaces that enable smooth integration into our existing production structures are key components of our scaling. We are therefore investing in an expanded technology portfolio with precisely these requirements and in systems with larger installation spaces.

In the plastics sector, we rely on fully production-ready systems wherever possible. Where the market does not yet offer these, we procure systems that are manufactured precisely to our requirements. In future, we will make greater use of systems that reliably meet the high requirements of our plants.

In the metal sector, we have already integrated key sub-processes from the IDAM project into our campus infrastructure. The next step will be the introduction of a completely new generation of metal 3D printers. We are also scouting intensively on campus and testing new technologies, materials and processes, which we are gradually transferring to the BMW Group process landscape. A current example of this is the integration of new production technologies such as Wire Arc Additive Manufacturing (WAAM) into the BMW Group production network.

Another decisive factor is the qualification of our development and production employees worldwide. By broadly anchoring AM expertise, we create the basis for sustainable scaling throughout the company.

Where is this leading? Which components are the focus?
Scaling will enable us to produce larger components with significantly improved properties across the entire product development process - and with a much shorter lead time. This means we no longer need tools for many applications, which significantly increases flexibility and speed.

In development, additive processes are already enabling highly functional components that can be used in dynamic functional runs and even crash tests, with qualities that could previously only be achieved using test tools. The new generation of highly productive, automated systems at the AM Campus leads to significantly faster and more efficient production. The larger installation spaces enable the production of large, one-piece and highly functional components. As a result, we are opening up significantly more applications in prototype construction and increasing the use of the technology.

In series production, we expect larger components in higher quantities in the coming years thanks to highly productive systems. WAAM significantly accelerates the production of large-format components and can be optimally integrated into our existing systems. In the production system itself, fast, robust and user-friendly systems ensure that our plants worldwide can manufacture additive production aids independently, quickly and decentrally. This increases efficiency throughout the entire development and production network.

Your outlook: What happens next?
In the short term, we are concentrating on integrating the new generation of systems. This puts us clearly on course for the broad industrialization of additive manufacturing. In terms of technology, we are in the process of fully transferring WAAM to series production. The process is already firmly established in prototype development, vehicle testing has been underway since 2025 and we will start series production of the first components in 2027.